U.S. patent application number 17/039449 was filed with the patent office on 2021-10-28 for power module assembly.
The applicant listed for this patent is LG ELECTRONICS INC.. Invention is credited to Seongmoo CHO, Siho CHOI, Kwangsoo KIM, Gun LEE.
Application Number | 20210337703 17/039449 |
Document ID | / |
Family ID | 1000005169050 |
Filed Date | 2021-10-28 |
United States Patent
Application |
20210337703 |
Kind Code |
A1 |
LEE; Gun ; et al. |
October 28, 2021 |
POWER MODULE ASSEMBLY
Abstract
The present disclosure relates to a power module assembly, and
may include a plurality of cooling fins on an upper cover covering
an upper portion of a module housing and a lower cover covering a
lower portion of the module housing to cool the power module
received inside the module housing, and the plurality of cooling
fins may constitute a cooling passage to allow coolant to flows
into the module housing, and expand a heat exchange area of the
power module, thereby improving the cooling performance of the
power module.
Inventors: |
LEE; Gun; (Seoul, KR)
; CHO; Seongmoo; (Seoul, KR) ; KIM; Kwangsoo;
(Seoul, KR) ; CHOI; Siho; (Seoul, KR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
LG ELECTRONICS INC. |
Seoul |
|
KR |
|
|
Family ID: |
1000005169050 |
Appl. No.: |
17/039449 |
Filed: |
September 30, 2020 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H05K 7/20145 20130101;
H05K 5/0256 20130101; H05K 5/03 20130101; H05K 7/20409
20130101 |
International
Class: |
H05K 7/20 20060101
H05K007/20; H05K 5/02 20060101 H05K005/02; H05K 5/03 20060101
H05K005/03 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 28, 2020 |
KR |
10-2020-0051608 |
Claims
1. A power module assembly, comprising: a module housing including
a power module for power conversion; an upper cover disposed at an
upper portion of the module housing to cover the upper portion of
the module housing with the power module interposed there between;
a lower cover disposed at a lower portion of the module housing to
cover the lower portion of the module housing with the power module
interposed there between; and a plurality of first cooling fins
protruding from an inner side of the upper cover toward a first
side surface of the power module and defining a first cooling
passage at an inner side of the upper cover.
2. The power module assembly of claim 1, further comprising: a
plurality of second cooling fins protruding from an inner side of
the lower cover toward a second side surface of the power module
and defining a second cooling passage at an inner side of the lower
cover.
3. The power module assembly of claim 2, wherein each of the
plurality of first cooling fins and the plurality of second cooling
fins is in contact with the power module to expand a heat exchange
area between coolant flowing into the first cooling passage and the
second cooling passage and the power module.
4. The power module assembly of claim 2, wherein a protruding end
portion of each of the plurality of first cooling fins and the
plurality of second cooling fins is flat.
5. The power module assembly of claim 2, wherein each of the
plurality of first cooling fins and the plurality of second cooling
fins has a circular cross-sectional shape.
6. The power module assembly of claim 2, wherein each of the
plurality of first cooling fins and the plurality of second cooling
fins has a gradually decreasing diameter from an inner surface of
each of the upper cover and the lower cover toward the power
module.
7. The power module assembly of claim 2, wherein the power module
is provided in plurality, the plurality of power modules being
arranged in parallel and in the same plane, and each of the
plurality of first cooling fins and the plurality of second cooling
fins has the same protruding length.
8. The power module assembly of claim 2, wherein the power module
is provided in plurality, the plurality of power modules being
arranged spaced apart in a length direction in the module housing,
and the plurality of first cooling fins and the plurality of second
cooling fins are arranged spaced apart in horizontal and vertical
directions, and the plurality of first cooling fins and the
plurality of second cooling fins each constitute a group to overlap
with the power module in a top-down direction, and a plurality of
first cooling fin groups and a plurality of second cooling fin
groups are arranged with a distance larger than that between the
plurality of first cooling fins or between the plurality of second
cooling fins.
9. The power module assembly of claim 8, wherein at least one of
the plurality of first cooling fins and the plurality of second
cooling fins are arranged in a plurality of rows in horizontal and
vertical directions, and among the plurality of rows, the cooling
fins in odd rows and the cooling fins in even row are alternately
arranged relative each other at equal intervals.
10. The power module assembly of claim 2, wherein the power module
is received inside the module housing, and a heating surface of the
power module is exposed to the first cooling passage and the second
cooling passage through an opening portion of the module housing in
a top-down direction.
11. The power module assembly of claim 2, wherein the power module
is provided in plurality, the plurality of power modules being
received inside the module housing and spaced apart, and wherein
the module housing further comprises: a plurality of receiving
portions arranged to pass there through in a top-down direction to
expose a heating surface of the power module, and arranged to pass
there through in a lateral direction to protrude a plurality of
terminals provided on both side surfaces of the power module,
respectively, so as to receive each of the plurality of power
modules; and a plurality of communication holes arranged to pass
there through in a top-down direction to communicate between the
first cooling passage and the second cooling passage.
12. The power module assembly of claim 2, further comprising: a
plurality of recess portions arranged to face each other on both
side surfaces of the module housing, respectively, and defined to
be concave along a circumference of the module housing; and a
plurality of fastening protrusions arranged to protrude from an
inner surface of each of the upper cover and the lower cover so as
to be fitted to both sides of the recess portion, and spaced apart
in a direction crossing both sidewalls of the recess portion with
the plurality of first cooling fins interposed there between.
13. The power module assembly of claim 2, comprising: a coolant
inlet port provided at a first side of the upper cover, and
disposed to communicate with the first cooling passage; and a
coolant outlet port provided at a second side of the upper cover,
and disposed to communicate with the first cooling passage.
14. The power module assembly of claim 2, further comprising: a
coolant inlet port provided at a first side of the upper cover, and
disposed to communicate with the first cooling passage; and a
coolant outlet port provided at a second side of the lower cover,
and disposed to communicate with the second cooling passage.
15. The power module assembly of claim 2, further comprising: a
plurality of coolant inlet ports provided at a first side of the
module housing, and arranged to communicate with one side of each
of the first cooling passage and the second cooling passage; and a
plurality of coolant outlet ports provided at a second side of the
module housing, and arranged to communicate with the other side of
each of the first cooling passage and the second cooling
passage.
16. The power module assembly of claim 2, wherein the first cooling
fins and the second cooling fins comprise aluminum or an aluminum
alloy, and are integrally formed on the upper cover and the lower
cover, respectively.
17. A power module assembly, comprising: a module housing including
a power module for power conversion; an upper cover disposed at an
upper portion of the module housing to cover the upper portion of
the module housing; a lower cover disposed at a lower portion of
the module housing to cover the lower portion of the module
housing; and a plurality of cooling fins each protruding toward a
first side and a second side of the power module from an inner side
surface of each of the upper cover and the lower cover so as to be
in contact with the power module.
18. The power module assembly of claim 17, further comprising: a
plurality of cooling passages disposed at upper and lower portions
of the module housing, respectively, for the passage of coolant to
cool the power module; and a coolant inlet port and a coolant
outlet port respectively disposed at both end portions of at least
one of the upper cover, the lower cover, and the module
housing.
19. The power module assembly of claim 17, wherein the plurality of
cooling fins are arranged spaced apart by a plurality of rows in a
first direction that is a length direction of the module housing
and a second direction crossing the first direction, and a
plurality of cooling fins adjacent to each other in the first
direction or the second direction are alternately arranged relative
each other.
20. The power module assembly of claim 18, wherein each of the
plurality of cooling passage comprises: an inlet region
communicating with the coolant inlet port to allow the coolant to
flow into the cooling passage; a plurality of main heat transfer
regions in which the plurality of cooling fins are arranged to
transfer heat between the coolant and the plurality of cooling fins
or between the power module and the plurality of cooling fins; a
plurality of intermediate header regions arranged between the
plurality of main heat transfer regions; and an outlet region
communicating with the coolant outlet port to allow the coolant to
flow out of the module housing.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Pursuant to 35 U.S.C. .sctn. 119(a), this application claims
the benefit of an earlier filing date of and the right of priority
to Korean Patent Application No. 10-2020-0051608, filed Apr. 28,
2020, the contents of which are incorporated by reference herein in
its entirety.
BACKGROUND
1. Technical Field
[0002] The present disclosure relates to a power module assembly
capable of maximizing a heat dissipation effect.
2. Description of the Related Art
[0003] An eco-friendly vehicle powered by hydrogen or electricity
includes a power conversion device such as an inverter.
Furthermore, among the core components of the power conversion
device, there is a power module assembly composed of a plurality of
power modules.
[0004] For the power module assembly, technology for improving the
performance of eco-friendly vehicles is being developed.
[0005] A power module provided in the power module assembly
exhibits a high amount of heat around electronic devices during
operation, and a rise in temperature of the power module directly
affects the performance and durability of the power module.
[0006] Accordingly, the main technical development fields of the
power module may include further improving the cooling performance
of the power module.
[0007] US 2014/0327127 A1 (hereinafter, Patent Document 1)
discloses a power module having a cooling structure.
[0008] In order to cool the power module, aluminum cooling fins
formed in a ribbon shape may be bonded to a copper layer of a
direct copper bonding (DCB) substrate by an ultrasonic bonding
process.
[0009] Coolant flows along the cooling fins to cool heat generated
by the copper layer of the power module.
[0010] However, the power module of Patent Document 1 has the
following problems.
[0011] First, a bonding portion of the cooling fin may be corroded
due to being in contact with coolant to weaken a bonding strength
of the cooling fin.
[0012] Furthermore, the bonding strength of the cooling fin may be
weakened due to the accumulation of fracture fatigue at a joint
portion between the cooling fin and the copper layer to cause
separation or peeling between the cooling fin and the copper layer,
thereby reducing cooling performance.
[0013] Second, a bonding process for bonding the cooling fin to the
power module and an inspection process thereof must be additionally
carried out.
[0014] In addition, during the bonding process of the cooling fin,
cracks may be caused in a ceramic layer of the DCB, resulting in
unstable process and reduced reliability of components.
SUMMARY
[0015] A first aspect of the present disclosure is to provide a
power module assembly capable of maximizing cooling performance of
a power module without bonding a cooling fin to the power
module.
[0016] Furthermore, another aspect of the present disclosure is to
provide a power module assembly capable of assembling a cooling
structure without adding a bonding process of the cooling fin to
the power module, thereby securing process stability and improving
component reliability.
[0017] In order to solve such problems of the present disclosure so
as to achieve the foregoing first object, a power module assembly
according to the present disclosure may include a module housing
having a power module for power conversion; an upper cover mounted
to cover an upper portion of the module housing with the power
module interposed therebetween; a lower cover mounted to cover a
lower portion of the module housing with the power module
interposed therebetween; and a plurality of first cooling fins
protruding from an inner side of the upper cover toward one side
surface of the power module to define a first cooling passage at an
inner side of the upper cover.
[0018] According to an example associated with the present
disclosure, the power module assembly may further include a
plurality of second cooling fins protruding from an inner side of
the lower cover toward the other side surface of the power module
to define a second cooling passage at an inner side of the lower
cover so as to dissipate heat in both direction from both side
surfaces of the power module.
[0019] According to an example associated with the present
disclosure, each of the plurality of first cooling fins and the
plurality of second cooling fins may be in contact with the power
module to expand a heat exchange area between coolant flowing into
the first cooling passage and the second cooling passage and the
power module.
[0020] According to an example associated with the present
disclosure, a protruding end portion of each of the plurality of
first cooling fins and the plurality of second cooling fins may be
defined in a flat shape.
[0021] According to an example associated with the present
disclosure, each of the plurality of first cooling fins and the
plurality of second cooling fins may be defined in a circular
cross-sectional shape.
[0022] According to an example associated with the present
disclosure, each of the plurality of first cooling fins and the
plurality of second cooling fins may be defined to have a diameter
gradually decreasing from an inner surface of each of the upper
cover and the lower cover toward the power module.
[0023] According to an example associated with the present
disclosure, a plurality of the power modules may be arranged in
parallel on the same plane, and each of the plurality of first
cooling fins and the plurality of second cooling fins may have the
same protruding length.
[0024] According to an example associated with the present
disclosure, a plurality of the power modules may be arranged to be
spaced apart in a length direction in the module housing, and the
plurality of first cooling fins and the plurality of second cooling
fins may be arranged to be spaced apart in horizontal and vertical
directions, and the plurality of first cooling fins and the
plurality of second cooling fins each may constitute a group to
overlap with the power module in a top-down direction, and a
plurality of first cooling fin groups and a plurality of second
cooling fin groups may be arranged with a distance larger than that
between the plurality of first cooling fins or between the
plurality of second cooling fins.
[0025] According to an example associated with the present
disclosure, the plurality of first cooling fins or the plurality of
second cooling fins may be arranged in a plurality of rows in
horizontal and vertical directions, and among the plurality of
rows, the cooling fins in odd rows and the cooling fins in even row
may be alternately arranged to each other at equal intervals.
[0026] According to an example associated with the present
disclosure, the power module may be received inside the module
housing, and a heating surface of the power module may be exposed
to the first cooling passage and the second cooling passage through
an opening portion disposed to pass through the module housing in a
top-down direction.
[0027] According to an example associated with the present
disclosure, a plurality of the power modules may be received inside
the module housing to be spaced apart, and the module housing may
include a plurality of receiving portions arranged to pass
therethrough in a top-down direction to expose a heating surface of
the power module, and arranged to pass therethrough in a lateral
direction to protrude a plurality of terminals provided on both
side surfaces of the power module, respectively, so as to receive
each of the plurality of power modules; and a plurality of
communication holes arranged to pass therethrough in a top-down
direction to communicate between the first cooling passage and the
second cooling passage.
[0028] According to an example associated with the present
disclosure, the power module assembly may include a plurality of
recess portions arranged to face each other on both side surfaces
of the module housing, respectively, and defined to be concave
along a circumference of the module housing; and a plurality of
fastening protrusions arranged to protrude from an inner surface of
each of the upper cover and the lower cover so as to be fitted to
both sides of the recess portion, and spaced apart in a direction
crossing both sidewalls of the recess portion with the plurality of
first cooling fins interposed therebetween.
[0029] According to an example associated with the present
disclosure, the power module assembly may include a coolant inlet
port provided at one side of the upper cover, and disposed to
communicate with the first cooling passage; and a coolant outlet
port provided at the other side of the upper cover, and disposed to
communicate with the first cooling passage.
[0030] According to an example associated with the present
disclosure, the power module assembly may include a coolant inlet
port provided at one side of the upper cover, and disposed to
communicate with the first cooling passage; and a coolant outlet
port provided at the other side of the lower cover, and disposed to
communicate with the second cooling passage.
[0031] According to another example associated with the present
disclosure, the power module assembly may include a plurality of
coolant inlet ports provided at one side of the module housing, and
arranged to communicate with one side of each of the first cooling
passage and the second cooling passage; and a plurality of coolant
outlet ports provided at the other side of the module housing, and
arranged to communicate with the other side of each of the first
cooling passage and the second cooling passage.
[0032] According to an example associated with the present
disclosure, the first cooling fins and the second cooling fins may
be formed to include aluminum or an aluminum alloy, and integrally
formed on the upper cover and the lower cover, respectively.
[0033] The effects of the power module assembly according to the
present disclosure will be described as follows.
[0034] First, a plurality of cooling fins may be disposed to
protrude from inner surfaces of an upper cover and a lower cover
respectively covering upper and lower portions of a module housing
in which the power module is accommodated.
[0035] The plurality of cooling fins may define a plurality of
cooling passages, thereby allowing coolant to flow through each of
the upper cover and the lower cover. The power module may be in
contact with coolant flowing along the cooling passages, thereby
allowing heat generated from the power module to be transferred to
the coolant. The power module may be cooled by coolant flowing
along the cooling passages.
[0036] Second, the plurality of cooling fins may be formed of an
aluminum or aluminum alloy material. The plurality of cooling fins
may be respectively in contact with both sides of the power module.
The cooling fins may have higher thermal conductivity than water,
thereby allowing heat generated from the power module to be
conducted to the plurality of cooling fins faster than coolant.
[0037] The plurality of cooling fins may expand a heat exchange
area of the power module, thereby improving the cooling performance
of the power module, and maximizing the cooling efficiency of the
power module.
[0038] Third, the plurality of cooling fins may be made of the same
metal material as the cover. Accordingly, the heat of the power
module may be transferred to a cover through the cooling fins so as
to be directly dissipated from the cover to an outer side of the
module housing.
[0039] Fourth, the plurality of cooling fins may be integrally
formed on each of the upper cover and the lower cover, and thus a
separate bonding process may not be required. For example, aluminum
cooling fins in the related art must be bonded to the power module,
and the bonded cooling fins may be corroded by being in contact
with coolant, thereby causing the separation/peeling of the cooling
fins due to weakening of a bonding strength of the cooling fins.
However, an integral structure of the cooling fins according to the
present disclosure may solve the foregoing problems in the related
art.
[0040] The plurality of cooling fins may be integrally formed on a
cover of the power module assembly prior to manufacturing the
cover, thereby simplifying an entire assembly process of the power
module assembly. On the contrary, the structure of the cooling fins
in the related art has a structure in which the cooling fins are
ribbon-bonded to the power module, and thus an additional process
and an inspection process may be required, thereby increasing the
number of processes and complicating the manufacturing process.
[0041] Fifth, the plurality of cooling fins may be arranged to
overlap with the power module in a top-down direction, and disposed
at equal intervals in horizontal and vertical directions of the
cover, thereby uniformly distributing the heat of the power
module.
[0042] Sixth, the plurality of cooling fins may be arranged in a
plurality of rows in horizontal and vertical directions in a
cooling passage, and the cooling fins in odd rows and the cooling
fins in even rows may be alternately arranged to each other,
thereby allowing coolant that has passed through a passage between
the cooling fines in odd rows to collide with the next cooling fins
in even rows so as to improve heat transfer performance and heat
exchange efficiency between the coolant and the cooling fins.
[0043] Seventh, the plurality of cooling fins may be defined in a
circular cross-sectional shape. Accordingly, even though the flow
of coolant flowing along the cooling passage collides with the
plurality of cooling fins, the resistance of the cooling fins may
be minimized.
[0044] Eighth, the plurality of cooling fins may be defined in a
conical shape. One end of the cooling fin may be in contact with
the power module in a flat shape, and the other end of the cooling
fin may be integrally connected to the cover. The cooling fin may
be defined to be inclined in a larger diameter from one end to the
other end thereof. The inclined side structure of the cooling fins
may increase a supporting force of the cover. In addition, as a
contact area between the coolant and the cooling fin increases from
one end of the cooling fin to the other end thereof, heat generated
from the power module may move from one end of the cooling fin to
the other end thereof to be in contact with the coolant in an
extended area, thereby improving cooling efficiency.
[0045] Ninth, a structure of the plurality of cooling fins defining
a cooling passage may be applied to the upper cover and the lower
cover without concentrating on the power module, thereby maximizing
the heat dissipation effect.
BRIEF DESCRIPTION OF THE DRAWINGS
[0046] FIG. 1 is a perspective view showing a power module assembly
according to the present disclosure.
[0047] FIG. 2 is an exploded view of the power module assembly in
FIG. 1.
[0048] FIG. 3 is a conceptual exploded view showing a state in
which a module housing and a power module are disassembled in FIG.
2.
[0049] FIG. 4 is a conceptual view showing a cross-section of the
power module in FIG. 3.
[0050] FIG. 5 is a conceptual view showing a state in which cooling
fins in FIG. 3 are in contact with the power module protruding from
a lower cover.
[0051] FIG. 6 is a cross-sectional view showing a movement path of
coolant in FIG. 1.
[0052] FIGS. 7A and 7B are a conceptual view showing a state in
which a coolant inlet port and a coolant outlet port are disposed
at different positions according to another embodiment of the
present disclosure.
[0053] FIGS. 8A and 8B are a conceptual view showing a state in
which a coolant inlet port and a coolant outlet port are disposed
at different positions according to still another embodiment of the
present disclosure.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0054] Hereinafter, the embodiments disclosed herein will be
described in detail with reference to the accompanying drawings,
and the same or similar elements are designated with the same
numeral references regardless of the numerals in the drawings and
their redundant description will be omitted. A suffix "module" and
"unit" used for constituent elements disclosed in the following
description is merely intended for easy description of the
specification, and the suffix itself does not give any special
meaning or function. In describing an embodiment disclosed herein,
moreover, the detailed description will be omitted when specific
description for publicly known technologies to which the invention
pertains is judged to obscure the gist of the present invention.
Also, it should be understood that the accompanying drawings are
merely illustrated to easily explain an embodiment disclosed
herein, and therefore, they should not be construed to limit the
technological concept disclosed herein by the accompanying
drawings, and the concept of the present disclosure should be
construed as being extended to all modifications, equivalents, and
substitutes included in the concept and technological scope of the
invention.
[0055] It will be understood that, although the terms first,
second, etc. may be used herein to describe various elements, these
elements should not be limited by these terms. The terms are used
merely for the purpose to distinguish an element from the other
element.
[0056] It will be understood that when an element is referred to as
being "connected with" another element, the element can be directly
connected with the other element or intervening elements may also
be present. On the contrary, in case where an element is "directly
connected" or "directly linked" to another element, it should be
understood that any other element is not existed therebetween.
[0057] Singular expressions include plural expressions unless the
context clearly indicates otherwise.
[0058] Terms "include" or "has" used herein should be understood
that they are intended to indicate the existence of a feature, a
number, a step, a constituent element, a component or a combination
thereof disclosed in the specification, and it may also be
understood that the existence or additional possibility of one or
more other features, numbers, steps, constituent elements,
components or combinations thereof are not excluded in advance.
[0059] FIG. 1 is a perspective view showing a power module assembly
100 according to the present disclosure.
[0060] FIG. 2 is an exploded view of the power module assembly 100
in FIG. 1.
[0061] FIG. 3 is a conceptual exploded view showing a state in
which a module housing 110 and a power module 120 are disassembled
in FIG. 2.
[0062] FIG. 4 is a conceptual view showing a cross-section of the
power module 120 in FIG. 3.
[0063] FIG. 5 is a conceptual view showing a state in which the
cooling fins 133 in FIG. 3 are in contact with the power module 120
protruding from a lower cover 131.
[0064] FIG. 6 is a cross-sectional view showing a movement path of
coolant in FIG. 1.
[0065] The power module assembly 100 of the present disclosure may
be one of core components constituting a power conversion device of
an eco-friendly electric vehicle.
[0066] The power module assembly 100 of the present disclosure
includes a module housing 110, an upper cover 130, and a lower
cover 131.
[0067] The module housing 110 defines an appearance of the power
module assembly 100 together with the upper cover 130 and the lower
cover 131.
[0068] The module housing 110 may be defined in a rectangular shape
having a vertical length that is larger than a horizontal
length.
[0069] A height of the module housing 110 may be disposed to be
shorter than the horizontal length and the vertical length of the
module housing 110.
[0070] One or more power modules 120 may be provided inside the
module housing 110.
[0071] In the present embodiment, it is shown that the plurality of
power modules 120 have three power modules.
[0072] The power module 120 is configured to convert power. A
plurality of first terminals 125 and a plurality of second
terminals 126 may be arranged on one side and the other side of the
power module 120, respectively.
[0073] The power module 120 may include a dielectric layer 121, a
metal layer 122, 123, and an electronic device 124.
[0074] The dielectric layer 121 may include an insulating material.
The dielectric layer 121 may include a ceramic material as an
insulating material.
[0075] The metal layer 122, 123 may be formed of a metal, and may
be bonded to at least one of both surfaces of the dielectric layer
121.
[0076] In the present embodiment, the metal layer may be composed
of a first metal layer 122 and a second metal layer 123 bonded on
both sides of the dielectric layer 121, respectively.
[0077] The first metal layer 122 and the second metal layer 123 may
be formed of a copper material.
[0078] The electronic device 124 may be mounted on the metal layer
122, 123.
[0079] The electronic device 124 is configured to implement a power
conversion function of the power module 120. One or more electronic
devices 124 may be provided on the metal layer. In the present
embodiment, it is shown that one electronic device 124 is mounted
on the metal layer.
[0080] A solder layer (not shown) made of solder between the
electronic device 124 and the metal layer 122, 123 may be provided
to electrically connect the electronic device 124 and the metal
layer.
[0081] An electrical connection between the electronic device 124
and the metal layer, 122, 123 may be made using a method other than
soldering.
[0082] The electronic device 124 may be implemented as a power
semiconductor device.
[0083] The power semiconductor device may be composed of any one
of, for example, an insulated gate transistor (IGBT), a bipolar,
and a power MOSFET (Metal Oxide Silicon Field Effect
Transistor).
[0084] Heat generated from the electronic device 124 may be
dissipated through the metal layer.
[0085] At least part of the metal layer 122, 123 may be exposed to
a cooling passage 134 disposed to allow coolant to flow into the
module housing 110.
[0086] Accordingly, part of the power module 120 may be cooled by
the coolant.
[0087] The module housing 110 may include an upper housing 111 and
a lower housing 112.
[0088] The upper housing 111 and the lower housing 112 are coupled
to each other to surround the power module 120.
[0089] The upper housing 111 and the lower housing 112 may be
formed into one body by insert injection molding with the power
module 120 interposed therebetween.
[0090] The insert injection molding refers to a configuration that
is inserted inside a mold, for example, a molding method in which a
component such as the power module 120 is disposed at a
predetermined position.
[0091] The mold may include a first mold corresponding to the upper
housing 111 and a second mold corresponding to the lower housing
112.
[0092] According to this configuration, the upper housing 111 and
the lower housing 112 may not only protect the power module 120 by
wrapping, but also may eliminate the use of various fastening
members for mechanical assembly between the upper housing 111 and
the lower housing 112 and a sealing member for sealing the cooling
passage 134 through which coolant flows.
[0093] Accordingly, the module housing 110 may eliminate the use of
the fastening member 101 and the sealing member, thereby reducing
an overall size of the power module assembly 100.
[0094] A plurality of receiving portions 114 are provided inside
the module housing 110. The plurality of receiving portions 114 are
configured to respectively receive a plurality of power modules
120.
[0095] The plurality of receiving portions 114 are arranged to be
spaced apart from each other in a vertical direction of the module
housing 110.
[0096] The receiving portion 114 is disposed in a horizontal
direction of the module housing 110 so as to allow the terminals of
the power module 120 to pass therethrough.
[0097] The receiving portion 114 is disposed to pass through the
module housing 110 in a top-down direction to dissipate the heat of
the power module 120.
[0098] The upper cover 130 is mounted on an upper portion of the
module housing 110 to cover the upper portion of the module housing
110, that is, an upper side of the plurality of receiving portions
114.
[0099] The lower cover 131 is mounted on a lower portion of the
module housing 110 to cover the lower portion of the module housing
110, that is, a lower side of the plurality of accommodating
portions 114.
[0100] Each of the upper cover 130 and the lower cover 131 may be
defined in a plate shape.
[0101] The upper cover 130 and the lower cover 131 are arranged to
be spaced apart in a top-down direction with the module housing 110
interposed therebetween.
[0102] A plurality of cooling passages 134 may be arranged to allow
coolant to flow into the module housing 110.
[0103] The plurality of cooling passages 134 may include a first
cooling passage 1341 and a second cooling passage 1342.
[0104] The first cooling passage 1341 may be provided at an inner
side of the upper cover 130.
[0105] The first cooling passage 1341 is formed to face an upper
side of the receiving portion 114.
[0106] The second cooling passage 1342 may be provided at an inner
side of the lower cover 131.
[0107] The second cooling passage 1342 is disposed to face a lower
side of the receiving portion 114.
[0108] The first cooling passage 1341 and the second cooling
passage 1342 may be elongated along the vertical directions of the
upper cover 130 and the lower cover 131, respectively.
[0109] A coolant inlet port 136 and a coolant outlet port 137 may
be disposed on the upper cover 130.
[0110] The coolant inlet port 136 may be disposed at one side of
the upper cover 130. The coolant inlet port 136 may be disposed to
protrude upward from the upper cover 130 in a circular tube
shape.
[0111] The coolant outlet port 137 may be disposed at the other
side of the upper cover 130. The coolant outlet port 137 may be
disposed to protrude upward from the upper cover 130 in a circular
tube shape.
[0112] The coolant inlet port 136 and the coolant outlet port 137
may be disposed at both ends of the upper cover 130, respectively,
in a vertical direction.
[0113] The coolant inlet port 136 is disposed to communicate with
one side of the first cooling passage 1341. The coolant outlet port
137 is disposed to communicate with the other side of the first
cooling passage 1341.
[0114] Coolant may flow into the first cooling passage 1341 through
the coolant inlet port 136. In addition, the coolant may flow out
of the module housing 110 through the coolant outlet port 137 from
the first cooling passage 1341.
[0115] A plurality of fastening holes 102 may be arranged at an
edge of the module housing 110 to pass through the module housing
110 in a height direction thereof.
[0116] A plurality of fastening members 101 such as screws, etc.
may be inserted and fastened through the fastening holes 102
arranged in the upper cover 130 and the lower cover 131,
respectively, and the fastening holes 102 of the module housing 110
to fasten the cover 130 and the lower cover 131.
[0117] The module housing 110 may include recess portions 113. The
recess portions 113 are provided at upper and lower sides of the
module housing 110.
[0118] The recess portions 113 may be defined to be concave along
an edge of the module housing 110.
[0119] The recess portions 113 are arranged at an inner side of the
module housing 110 so as to bypass the plurality of fastening holes
102. The recess portions 113 are disposed at an outer side of the
receiving portion 114.
[0120] A protruding portion 132 is provided on each of the upper
cover 130 and the lower cover 131.
[0121] The protruding portion 132 is disposed to protrude in a
thickness direction of the upper cover 130 or the lower cover 131.
The protruding portion 132 is configured to be received in the
recess portion 113.
[0122] The protruding portions 132 are disposed to be spaced from
outer ends of the upper cover 130 and the lower cover 131,
respectively, at a predetermined distance from each other.
[0123] The protruding portions 132 are disposed along the edges of
the upper cover 130 and the lower cover 131, respectively. The
protruding portion 132 may be defined in a closed loop shape.
[0124] A sealed groove 1321 may be disposed at an inner side of the
protruding portion 132. The sealed groove 1321 may be disposed to
have a very small width compared to its length.
[0125] A sealing ring 1322 is received in the sealed groove 1321.
The sealing ring 1322 may be formed of a rubber material. The
sealing ring 1322 is disposed to have a diameter equal to or
slightly larger than a width of the sealed groove 1321, and
configured to be coupled to the sealed groove 1321 by an
interference fit.
[0126] The sealing ring 1322 seals between the module housing 110
and the upper cover 130 or between the module housing 110 and the
lower cover 131, thereby preventing coolant from leaking into a gap
therebetween.
[0127] The recess portion 113 and the protruding portion 132 are
disposed to overlap with each other in a height direction or a
top-down direction of the module housing 110. An edge portion of
the module housing 110 is configured to surround an outer surface
of the protruding portion 132.
[0128] An inner surface of the edge portion of the module housing
110 and an outer surface of the protruding portion 132 are
configured to be in surface contact with each other.
[0129] According to this configuration, the edge portion of the
module housing 110 and the protrusion portion 132 may be disposed
in a structure overlapping with each other in an inward or outward
direction, thereby effectively sealing a gap between the module
housing 110 and the upper cover 130 and between the module housing
110 and the lower cover 131.
[0130] In addition, an overlapping structure between the edge
portion of the module housing 110 and the protrusion portion 132
may define a gap between the module housing 110 and the cover to be
curved in a top-down direction.
[0131] Accordingly, a movement distance of coolant moving from the
cooling passage 134 disposed at an inner side of the module housing
110 to an outer side of the module housing 110.
[0132] One or a plurality of power modules 120 may be provided in
the receiving portion 114 of the module housing 110. The plurality
of power modules 120 may include a first power module 120 to an
N-th power module 120. N may be a natural number above 2.
[0133] A plurality of communication holes are provided at an inner
side of the module housing 110. The plurality of communication
holes are configured to communicate between the first cooling
passage 1341 and the second cooling passage 1342.
[0134] The plurality of communication holes may include a first
communication hole 115 and a second communication hole 116.
[0135] The first communication hole 115 and the second
communication hole 116 may be disposed between the recess portion
113 and the receiving portion 114.
[0136] The first communication hole 115 may be disposed adjacent to
an inner side of one end portion of the recess portion 113.
[0137] The second communication hole 116 may be disposed adjacent
to an inner side of the other end portion of the recess 113.
[0138] The first communication hole 115 may be disposed to pass
through one side of the first cooling passage 1341 and one side of
the second cooling passage 1342 in a top-down direction to be
connected to each other. A first communication hole 115 may be
disposed to communicate with the coolant inlet port 136.
[0139] The coolant may flow into one side of the first cooling
passage 1341 through the coolant inlet port 136 or may flow into
one side of the second cooling passage 1342 through the first
communication hole 115.
[0140] Furthermore, coolant may be branched through the first
communication hole 115 to flow into the first cooling passage 1341
and the second cooling passage 1342.
[0141] The second communication hole 116 may be disposed to pass
through the other side of the first cooling passage 1341 and the
other side of the second cooling passage 1342 in a top-down
direction to connect to each other. The second communication hole
116 may be disposed to communicate with the coolant outlet port
137.
[0142] The coolant may be divided into two branches to move in one
direction along the first cooling passage 1341 and the second
cooling passage 1342, and then the coolant of the second cooling
passage 1342 may be merged with the coolant of the first cooling
passage 1341 while moving upward through the second communication
hole 116, and discharged through the coolant outlet port 137.
[0143] Each of the upper cover 130 and the lower cover 131 includes
a plurality of cooling fins 133.
[0144] The plurality of cooling fins 133 may include a plurality of
first cooling fins 1331 and a plurality of second cooling fins
1332.
[0145] The plurality of first cooling fins 1331 are provided on an
inner surface of the upper cover 130. The plurality of second
cooling fins 1332 are provided on an inner surface of the lower
cover 131.
[0146] The plurality of first cooling fins 1331 and the plurality
of second cooling fins 1332 differ only in their formation
positions, and have the same configuration and function as each
other. The following description of the cooling fins 133 may be
commonly applied to all of the first cooling fins 1331 and the
second cooling fins 1332 unless otherwise distinguished.
[0147] The plurality of cooling fins 133 may be disposed to
protrude toward the power module 120 from an inner surface of each
of the upper cover 130 and the lower cover 131.
[0148] The plurality of cooling fins 133 may protrude higher in a
top-down direction than a protruding length of the protruding
portion 132 on an inner surface of each of the upper cover 130 and
the lower cover 131.
[0149] The plurality of cooling fins 133 are arranged at an inner
side of a closed loop of the protruding portion 132 to be spaced
apart from each other. The protruding portion 132 may define an
outermost boundary of the cooling passage 134.
[0150] The plurality of cooling fins 133 are configured to define a
cooling passage 134.
[0151] The plurality of cooling fins 133 are configured to be in
contact with coolant. The coolant may flow between the plurality of
cooling fins 133.
[0152] One end of the cooling fins 133 is integrally formed on an
inner surface of each of the upper cover 130 and the lower cover
131. The upper cover 130 and the lower cover 131 are integrally
connected and supported.
[0153] The other end of the cooling fin 133 is configured to be in
contact with the power module 120. The other end of the cooling fin
133 is defined in a flat shape.
[0154] Accordingly, heat generated by the power module 120 may be
transferred to the plurality of cooling fins 133.
[0155] The plurality of cooling fins 133 may be formed of a metal
material having a high heat transfer coefficient. For example, the
plurality of cooling fins 133 may be formed of aluminum or an
aluminum alloy.
[0156] According to this configuration, the plurality of cooling
fins 133 may be formed of a metal material, thereby cooling the
power module 120 more efficiently than simply being in contact with
coolant with the power module 120.
[0157] For example, since aluminum has a thermal conductivity of
350 times greater than that of water, the heat of the power module
120 is transferred to the cooling fins 133 faster than the
coolant.
[0158] The heat of the power module 120 may be transferred not only
by being in contact with the coolant, but also by being in contact
with the cooling fins 133.
[0159] The cooling fins 133 may expand a heat exchange area between
the power module 120 and the coolant.
[0160] Each of the upper cover 130 and the lower cover 131 may be
formed of aluminum or an aluminum alloy, which is the same material
as the cooling fins 133.
[0161] Accordingly, the cooling fins 133 not only transfer the heat
of the power module 120 to coolant by defining a passage of the
coolant, but also expand the heat exchange area to transfer the
heat of the power module 120 to the upper cover 130 and the lower
cover 131, thereby dissipating heat into the atmosphere.
[0162] The cooling fins 133 may be defined in a circular shape to
minimize a flow resistance of coolant.
[0163] Each of the plurality of cooling fins 133 may be disposed to
protrude in a smaller diameter toward the power module 120 from an
inner surface of each of the upper cover 130 and the lower cover
131.
[0164] The cooling fin 133 may be defined in a conical shape. An
outer surface of the cooling fin 133 may be disposed to be
inclined. The coolant may be in contact with an outer surface of
the cooling fins 133.
[0165] According to this configuration, a cross-sectional area of
one end of the cooling fin 133 supported by the cover may be larger
than that of the other end of the cooling fin 133 in contact with
the power module 120, thereby enhancing a supporting force of the
cover with respect to the cooling fin 133.
[0166] Furthermore, as a contact area with coolant and a heat
transfer area to the cover increase from one end of the cooling fin
133 to the other end of the cooling fin 133, thereby improving the
heat transfer performance and efficiency of the cooling fin
133.
[0167] In addition, as a heat transfer direction of the cooling fin
133 goes from the transfer module to the cover, the heat transfer
area increases.
[0168] Moreover, since a cross-sectional shape of the cooling fin
133 is circular, the heat transfer direction of the cooling fin 133
may be transferred in a radial direction.
[0169] The plurality of cooling fins 133 may constitute a group for
each power module 120 and may be spaced apart at equal intervals.
For example, the plurality of cooling fins 133 may be spaced at
equal intervals in a range of 1 to 2 times their diameter.
[0170] A distance between the plurality of cooling fins 133 may be
changed according to the size and area of the power module 120.
[0171] The plurality of cooling fins 133 may be spaced apart from
each other in a first direction crossing both side surfaces of the
protruding portion 132 having a larger length in a vertical
direction and a second direction crossing both side surfaces of the
protruding portion 132 having a smaller length in horizontal
direction.
[0172] The plurality of cooling fins 133 may be spaced apart from
the cooling passage 134 in a first row to an L-th row in the first
direction (horizontal direction). L is a natural number above
2.
[0173] Alternatively, the plurality of cooling fins 133 may be
spaced apart from the cooling passage 134 in a first row to an M-th
row in the second direction (vertical direction). M is a natural
number above 2. The first direction and the second direction may
cross perpendicular to each other.
[0174] The plurality of cooling fins 133 may be spaced apart in L*M
rows.
[0175] For the plurality of cooling fins 133, odd and even rows may
be alternately arranged to each other in the first or the second
direction.
[0176] According to a mutually staggered arrangement structure of
the cooling fins 133, the cooling fins 133 in odd rows and the
cooling fins 133 in even rows are arranged in a non-overlapping
manner in the first direction or the second direction.
[0177] Furthermore, the cooling fins 133 in odd rows and the
cooling fins 133 in even rows may be spaced apart to overlap with
each other in a rectangular diagonal direction.
[0178] According to the arrangement structure of the cooling fins
133, when coolant flows along the first direction or the second
direction in the cooling passage 134, the coolant may pass between
two adjacent cooling fins 133 in odd rows and then collide with the
cooling fins 133 in even rows, thereby more quickly and efficiently
exchanging heat between the coolant and the cooling fins 133.
[0179] In addition, the cooling fins 133 in odd rows and the
cooling fins 133 in even rows may be alternately arranged at equal
intervals, and the plurality of cooling fins 133 may distribute
heat evenly to the cooling passage 134.
[0180] The plurality of cooling fins 133 may constitute three
groups corresponding to the number of power modules 120.
[0181] The plurality of cooling fins 133 may be intensively
arranged on a metal plate that is a heating portion of the power
module 120.
[0182] The plurality of cooling fins 133 are disposed to overlap
with the power module 120 in a thickness direction or a top-down
direction.
[0183] Relatively less heat may be generated in a space between the
power modules 120.
[0184] The plurality of cooling fins 133 may not be disposed in a
space between the power modules 120.
[0185] The first cooling fin 1331 disposed in the first cooling
passage 1341 and the second cooling fin 1332 disposed in the second
cooling passage 1342 may be arranged in a vertically symmetrical
manner around the power module 120.
[0186] Furthermore, the plurality of cooling fins 133 may be
arranged in a horizontally symmetrical manner in a vertical
direction of the cooling passage 134.
[0187] A plurality of fastening protrusions 117 may be provided at
an inner side of each of the upper cover 130 and the lower cover
131.
[0188] The fastening protrusions 117 are configured to fasten the
upper cover 130 and the lower cover 131 to upper and lower sides of
the module housing 110.
[0189] The plurality of fastening protrusions 117 may have a small
width to be elongated in a vertical direction of the cover.
[0190] The plurality of fastening protrusions 117 may be disposed
to protrude in a top-down direction toward the power module 120
from an inner surface of each of the upper cover 130 and the lower
cover 131.
[0191] The fastening protrusion 117 may protrude higher than a
protruding length of the protruding portion 132 and lower than a
protruding length of the cooling fin 133.
[0192] The plurality of fastening protrusions 117 may be arranged
to be spaced apart in a horizontal direction at an inner side of
the protruding portion 132.
[0193] The plurality of fastening protrusions 117 may be arranged
to be spaced apart on both sides in a horizontal direction of the
group of cooling fins 133 with one group of cooling fins 133
interposed therebetween.
[0194] The plurality of fastening protrusions 117 may be disposed
in parallel for each pair for each group of cooling fins 133.
[0195] Each of the plurality of fastening protrusions 117 may
extend to correspond to a vertical length of one group of cooling
fins 133.
[0196] The plurality of fastening protrusions 117 may not be
arranged in a space between the plurality of groups of cooling fins
133.
[0197] Since the plurality of fastening protrusions 117 are
inserted into and coupled to the receiving portion 114, the upper
cover 130 or the lower cover 131 may be fastened to upper and lower
sides of the module housing 110, respectively.
[0198] Each of the first cooling passage 1341 and the second
cooling passage 1342 may be composed of an inlet region 1351, a
plurality of main heat transfer regions 1352, a plurality of
intermediate header regions 1353, and an outlet region 1354.
have.
[0199] Based on a flow direction of the coolant, each of the first
cooling passage 1341 and the second cooling passage 1342 may be
arranged in the order of the inlet region 1351, the main heat
transfer region 1352, the intermediate header region 1353, the main
heat transfer region 1352, the intermediate header region 1353, the
main heat transfer region 1352, and the outlet region 1354.
[0200] The plurality of cooling fins 133 may be arranged only in
the main heat transfer region 1352.
[0201] The inlet region 1351 is a region disposed adjacent to the
coolant inlet port 136 and connected to communicate with the
coolant inlet port 136.
[0202] The cooling fins 133 are arranged in the main heat transfer
region 1352. In the main heat transfer region 1352, the heat of the
power module 120 may be intensively dissipated through the
plurality of cooling fins 133.
[0203] The intermediate header region 1353 is disposed between the
plurality of main heat transfer regions 1352. Although the cooling
fins 133 are not disposed in the intermediate header region 1353,
coolant exiting from the main heat transfer region 1352 merges in
the intermediate header region 1353, thereby uniformly mixing
coolants with different temperatures due to different heat exchange
amounts for each region of the power module 120.
[0204] In addition, the intermediate header region 1353 may
distribute uniformly mixed coolant to a passage between the cooling
fins 133 of the main heat transfer region 1352.
[0205] The outlet region 1354 is a region disposed adjacent to the
coolant outlet port 137 and connected to communicate with the
coolant outlet port 137.
[0206] The coolant inlet port 136 and the coolant outlet port 137
may be connected to a radiator 142 of a vehicle through a coolant
circulation line 140.
[0207] A coolant circulation pump 141 may be provided in the
coolant circulation line 140.
[0208] The coolant circulation pump 141 may provide power to
coolant to circulate the coolant.
[0209] The radiator 142 may exchange heat with coolant received
from the power module assembly 100 with outside air, thereby
cooling the high-temperature coolant and then transferring the
cooled coolant to the power module assembly 100 again.
[0210] Looking at a circulation path of coolant, the coolant flows
to the coolant inlet port 136.fwdarw.the first cooling passage
1341/the second cooling passage 1342 (cooling of the power module
120).fwdarw.the coolant outlet port 137 at an inside of the power
module assembly 100, and flows to the circulation line
140.fwdarw.the radiator 142 (cooling of the coolant).fwdarw.the
circulation line 140 at an outside of the power module assembly
100, and circulates to the power module assembly 100 again.
[0211] FIGS. 7A and 7B are a conceptual view showing a state in
which a coolant inlet port 236 and a coolant outlet port 237 are
disposed at different positions according to another embodiment of
the present disclosure.
[0212] An embodiment shown in FIG. 7A differs from the embodiments
of FIGS. 1 through 6 in that the coolant inlet port 236 and the
coolant outlet port 237 are provided at both end portions of the
lower cover 131, respectively.
[0213] Part of coolant introduced through the coolant inlet port
236 flows into the inlet region 1351 of the second cooling passage
1342, and another part of the coolant is branched through the first
communication hole 115 to flow into the inlet region 1351 of the
first cooling passage 1341.
[0214] The coolant flows along the first cooling passage 1341 and
the second cooling passage 1342, respectively, to absorb heat from
both surfaces of the plurality of power modules 120 arranged in
series.
[0215] Then, coolant flowing out of the outlet region 1354 of the
first cooling passage 1341 merges with coolant flowing out of the
outlet region 1354 of the second cooling passage 1342 through the
second communication hole 116.
[0216] Subsequently, the merged coolant flows out through the
coolant outlet port 237, moves to the radiator 142 to be cooled,
and then flows back into the coolant inlet port 236.
[0217] Other components are the same or similar to those of the
foregoing embodiments of FIGS. 1 through 6, and thus redundant
descriptions thereof will be omitted.
[0218] An embodiment shown in FIG. 7B differs from the embodiments
of FIGS. 1 through 6 or the embodiment of FIG. 7A in that the
coolant inlet port 236 is disposed at one side of the lower cover
131, and the coolant outlet port 237 is disposed at the other side
of the upper cover 130.
[0219] Other components are the same as or similar to those of the
foregoing embodiments of FIGS. 1 through 6 or the embodiment of
FIG. 7A, and thus redundant descriptions thereof will be
omitted.
[0220] FIGS. 8A and 8B are a conceptual view showing a state in
which a coolant inlet port 336 and a coolant outlet port 337 are
disposed at different positions according to still another
embodiment of the present disclosure.
[0221] An embodiment shown in FIG. 8A differs from the embodiments
of FIGS. 1 through 6 in that the coolant inlet port 336 and the
coolant outlet port 337 are provided in the module housing 110.
[0222] One coolant inlet port 336 may be disposed at one side of
the module housing 110.
[0223] One coolant outlet port 337 may be disposed at the other
side of the module housing 110.
[0224] The coolant inlet port 336 and the coolant outlet port 337
may be disposed on side surfaces of the module housing 110 in
opposite directions, respectively.
[0225] The coolant inlet port 336 may be disposed on a front end
surface of the module housing 110 in a vertical direction. The
coolant inlet port 336 may be disposed to communicate with the
first communication hole 115.
[0226] The first communication hole 115 is disposed to be branched
in a top-down direction from the coolant inlet port 336, and
configured to connect one side of the first cooling passage 1341
and one side of the second cooling passage 1342.
[0227] Coolant may flow into the coolant inlet port 336, and is
branched in both directions from the first communication hole 115
to flow into the first cooling passage 1341 and the second cooling
passage 1342, respectively.
[0228] The coolant outlet port 337 may be disposed on a rear end
surface of the module housing 110 in a vertical direction. The
coolant outlet port 337 may be disposed to communicate with the
second communication hole 116.
[0229] The second communication hole 116 is disposed to merge in a
top-down direction in the outlet region 1354 of the first and
second cooling passages 1341, 1342, and configured to connect the
other side of the first cooling passage 1341 and the other side of
the second cooling passage 1342.
[0230] Coolant may flow out of the outlet region 1354 of the first
cooling passage 1341 and the outlet region 1354 of the second
cooling passage 1342, respectively, and merge in the second
communication hole 116 to be discharged through the coolant outlet
port 337 to an outside of the module housing 110.
[0231] In an embodiment shown in FIG. 8B, a plurality of coolant
inlet ports 336 and a plurality of coolant outlet ports 337 are
arranged in a plurality of rows on front and rear end surfaces of
the module housing 110, respectively.
[0232] The plurality of coolant inlet ports 336 and the plurality
of coolant outlet ports 337 may be arranged to be spaced apart in a
top-down direction of the module housing 110.
[0233] The plurality of coolant inlet ports 336 may include a first
coolant inlet port 336 and a second coolant inlet port 336.
[0234] The first coolant inlet port 336 may be disposed to
communicate with one side of the first cooling passage 1341.
[0235] The second coolant inlet port 336 may be disposed to
communicate with one side of the second cooling passage 1342.
[0236] The plurality of coolant outlets 337 may include a first
coolant outlet port 337 and a second coolant outlet port 337.
[0237] The first coolant outlet port 337 may be disposed to
communicate with one side of the first cooling passage 1341.
[0238] The second coolant outlet port 337 may be disposed to
communicate with the other side of the second cooling passage
1342.
[0239] Each of the plurality of coolant inlet ports 336 and the
plurality of coolant outlet ports 337 may correspond to the
plurality of cooling passages 134 on a one-to-one basis and may be
connected in parallel.
[0240] According to this configuration, a movement path of coolant
that connects between the plurality of coolant inlet ports 336 and
the inlet regions 1351 of the plurality of cooling passages 134,
respectively, may be disposed at the shortest distance, thereby
minimizing a flow resistance of fluid at a section without the
cooling fins 133.
[0241] Furthermore, a movement path of coolant that connects
between the outlet regions 1354 of the plurality of cooling
passages 134 and the plurality of coolant outlet ports 337,
respectively, may be disposed at the shortest distance, thereby
minimizing a flow resistance of fluid at a section without the
cooling fins 133.
[0242] Other components are the same or similar to those of the
foregoing embodiments of FIGS. 1 through 6, and thus redundant
descriptions thereof will be omitted.
[0243] Accordingly, according to the present disclosure, a
plurality of cooling fins 133 are disposed to protrude from inner
surfaces of the upper cover 130 and the lower cover 131,
respectively, covering upper and lower portions of the module
housing 110 in which the power module 120 is received.
[0244] The plurality of cooling fins 133 may constitute a plurality
of cooling passages 134 to allow coolant to flow through each of
the upper cover 130 and the lower cover 131. The power module 120
may be in contact with coolant flowing along the cooling passages
134 to transfer heat generated from the power module 120 to the
coolant. The power module 120 may be cooled by coolant flowing
along the cooling passages 134.
[0245] The plurality of cooling fins 133 are formed of an aluminum
or aluminum alloy material. The plurality of cooling fins 133 are
respectively in contact with both side surfaces of the power module
120. Since the cooling fins 133 have higher thermal conductivity
than water, heat generated from the power module 120 may be
conducted to the plurality of cooling fins 133 faster than
coolant.
[0246] The plurality of cooling fins 133 may expand a heat exchange
area of the power module 120, thereby improving the cooling
performance of the power module 120, and maximizing the cooling
efficiency of the power module 120.
[0247] The plurality of cooling fins 133 may be made of the same
metal material as the cover. Accordingly, the heat of the power
module 120 may be transferred to the cover through the cooling fins
133, and may be directly discharged from the cover to an outside of
the module housing 110.
[0248] Since the plurality of cooling fins 133 are integrally
formed on each of the upper cover 130 and the lower cover 131, a
separate bonding process is not required. For example, the aluminum
cooling fins 133 in the related art must be bonded to the power
module 120, and the bonded cooling fins may be corroded by being in
contact with coolant, thereby causing the separation/peeling of the
cooling fins 133 due to weakening of a bonding strength of the
cooling fins 133. However, an integral structure of the cooling
fins 133 according to the present disclosure may solve the
foregoing problems in the related art.
[0249] The plurality of cooling fins 133 may be integrally formed
on a cover of the power module assembly 100 prior to manufacturing
the cover, thereby simplifying an entire assembly process of the
power module assembly 100. On the contrary, the structure of the
cooling fins 133 in the related art has a structure in which the
cooling fins are ribbon-bonded to the power module 120, and thus an
additional process and an inspection process may be required,
thereby increasing the number of processes and complicating the
manufacturing process.
[0250] The plurality of cooling fins 133 may be disposed to overlap
with the power module 120 in a top-down direction, and disposed at
equal intervals in horizontal and vertical directions of the cover,
thereby uniformly distributing the heat of the power module
120.
[0251] The plurality of cooling fins 133 may be arranged in a
plurality of rows in horizontal and vertical directions in the
cooling passage 134, and the cooling fins 133 in odd rows and the
cooling fins 133 in even rows may be alternately arranged to each
other, thereby allowing coolant that has passed through a passage
between the cooling fines 133 in odd rows to collide with the next
cooling fins 133 in even rows so as to improve heat transfer
performance and heat exchange efficiency between the coolant and
the cooling fins 133.
[0252] The plurality of cooling fins 133 may be defined in a
circular cross-sectional shape. Accordingly, even when the flow of
coolant flowing along the cooling passage 134 collides with the
plurality of cooling fins 133, a resistance of the cooling fins 133
may be minimized.
[0253] The plurality of cooling fins 133 may be defined in a
conical shape. One end of the cooling fin 133 may be in contact
with the power module 120 in a flat shape, and the other end of the
cooling fin 133 may be integrally connected to the cover. The
cooling fin 133 may be defined to be inclined in a larger diameter
from one end to the other end thereof. The inclined side structure
of the cooling fins 133 may increase a supporting force of the
cover. In addition, as a contact area between the coolant and the
cooling fin 133 increases from one end of the cooling fin 133 to
the other end thereof, heat generated from the power module 120 may
move from one end of the cooling fin 133 to the other end thereof
to be in contact with the coolant in an extended area, thereby
improving cooling efficiency.
[0254] The structure of the plurality of cooling fins 133 defining
the cooling passage 134 may be applied to the upper cover 130 and
the lower cover 131 without concentrating on the power module,
thereby maximizing the heat dissipation effect.
* * * * *